INSTRUCTION MANUAL ~ COPYRIGHT 1984 BY STODDARD-HAMILTON AIRCRAFT, INC. PRINTBD IN U.S.A. ~ STODDARD-HAMILTON AIRCRAFT. INC()RP()AATED MODEL ASSEMBL'f NAME GLASAIR TD GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-1 THIS PAGE INTENTIONALLY LEFT BLANK ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED VOLUME MODEL REVISION DATE ASSEMBLY NAME PAGE I 1-2 GENERAL INFORMATION GLASAIR TD TABLE OF CONTENTS GENERAL INFORMATION SECTION 1 FABRICATION TECHNIQUES SECTION 2 WHEEL PANT ASSEMBLy SECTION A HORIZONTAL STABILIZER AND ELEVATOR ASSEMBLIES ................. SECTION B WING ASSEMBLy SECTION C FUSELAGE ASSEMBLy SECTION D RUDDER ASSEMBLy SECTION E AILERON AND FLAP ASSEMBLIES SECTION F FINAL ASSEMBLY SECTION G APPENDICES SECTION H ~ STODDARD-HAMILTON AIRCt?AFT. INCORPORATED MODEL ASSEMBL Y NAME GLASAIR TD GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-3 INTRODUCTION Welcome to the Glasair ranks. We hope that building and flying the Glasair airplane is a pleasant and rewarding experience. The intent of this manual is to simplify construction and give a step-by-step explanation of every construction procedure. Before beginning construction read this section and the following fabrication section thoroughly. Pay close attention to the safety precautions listed in this section. GENERAL CONSIDERATIONS Prior to beginning any construction the following general instructions should be considered. 1.) We suggest studying each alphabetical division in the individual assembly sections prior to beginning construction. This will give the builder a thorough understanding of what is to be accomplished, and will avoid any surprises. 2.) Make sure all the tools and materials required are on hand. 3.) Proceed in a stepwise manner paying close attention to the WARNINGS, CAUTIONS, and NOTES. 4.) After completing each alphabetical division in the individual assembly sections (such as wheelpant, or wing assembly) place a check mark in the little square box marked "COMPLETED". As a result, the builder will always know where he has left off. KIT STORAGE SUGGESTIONS Due to the nature of the construction of the Glasair airplane some care should be taken in storing the fiberglass composite shell parts. The composite shell parts individually do not have the structural integrity of completed assemblies. Therefore, the wing panels for example are free to bend and adapt to any shape they are subject to. Because of this "sets" can occur in any flat composite shell part while in storage. Proper storage is mandatory to keep the parts from warping or taking on sets. Parts that are most susceptable to this phenomena are the wing panels, aileron and flap panels, and the horizontal stabilizer and elevator panels. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-4 The best place to store the parts is in the shipping crate itself. All the parts are held in place with nylon strapping. Cut these straps to relieve any tension or pressure on the parts. If the parts cannot be stored in the crate, make sure the flat parts are stored in a flat position. To alleviate warpage, the wing panels are best left in the wooden yokes until needed. NOTE: If parts do become warped they can be corrected by applying pressure over a period of time in the opposite direction of the set. The shelf life of unpromoted resin is approximately 6 months, although it may last considerably longer depending upon storage conditions. The shelf life of the gelcoat is also approximately 6 months. Promoted resin has a shorter shelf life, also depending upon storage conditions. For this reason resin is only promoted in one gallon quantities at a time. Promoted resin that has been stored for a long period of time may become unusable. Test it to see if it has become unusually thick or lumpy. If so, discard and mix up a new one gallon batch of promoted resin. Store all these ingredients in a cool, dry, dark, well ventilated place. KIT BUILDING SEQUENCE We recommend building the aircraft in the sequence outllned In this manual starting with the wheel pants, and then proceeding to the horizontal stabilizer and elevator assemblies. After the horizontal stabilizer and elevator assemblies are complete the wing lS a good assembly to work on next, however this sequence is not mandatory. The fuselage could be started next, but at some point the wing will need to be completed for final assembly. The wing and fuselage assemblies must be completed before the aileron, flap, and rudder assemblies can be started. All assemblies should be complete before starting final assembly. ~ STODDARD-HAMILTON AIRCRAFT INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-5 RESIN AND GELCOAT SUPPLY Due to the limited shelf life c f resin, MEKP, and gelcoat, only three ga I Lou s of resin, 8 oz. of MEKP, and no gelcoat are shipped with the kit. Write or phone our shipping department when additional resin, catalyst, or gelcoat is needed. The gelcoat will not be needed until near the end of the project when all of the gelcoating can be done at once. All gelcoat in excess of one gallon will be invoiced. Builders pay the freight on all delay shipment items. REVISIONS Any revision to the Instruction Manual will be listed at the beginning of this section. The revision will be designated by a revision letter and date. The revised page will show the most current revision letter and date at the bottom of the page in the title block. Any page that shows no revision letter and date in the title block has never been revised and is the most current page availa ble. Upon receiving a revision to the manual, throwaway the old pages and insert the new ones supplied. If a revision changes a part of the airplane that has already been built, the aircraft does not need to be changed unless the revision is a mandatory change. Mandatory revisions will be so identified in the revision. A revision, however, that is not mandatory may be adhered to as long as it is feasible. It is up to the builder's discretion as to whether he wants to adhere to a non-mandatory revision if he is beyond that point in the manual. If a revision is mandatory the change must be adhered to. PROCUREMENT OF PARTS NOT SUPPL1ED IN KIT The existing Glasair kit supplied most parts necessary to build the airframe but not all parts needed to build the entire airplane complete. For parts that are not included in the kit, we can recommend suppliers and sources. ~ MODEL GLASA [R TD ASSEMBLY NAME GENERAL IN F O R ~ l A n O N STODDARD-HAMILTON AIRCRAFT, INCORPORATED REVISION B DATE VOLUME 10/31/86 1 PAGE 1-6 WARNINGS, CAUTIONS, AND NOTES The following definitions apply to WARNINGS, CAUTIONS, and NOTES throughout this Manual. 1.) WARNING---Procedures, practices, etc., which will result in personal injury or loss of life if not carefully followed. 2.) CAUTION---Procedures, practices, etc., which if not strictly observed will result in damage or destruction of a part. 3.) procedures, or instructions which are considered essential to emphasize. ISAFETY PRECAUTIONS I WARNING: For personal safety please heed the following safety precautions. I. EYE AND SKIN CONTAMINATION Due to the corrosive nature of the chemicals used to bond the Glasair together, care must be taken with them, especially the MEKP catalyst. The MEKP catalyst is a strong oxidizing agent. A. MEKP CATALYST: Keep away from fire. Harmful or fatal if swallowed. Harmful if inhaled. Severe eye irritant. One drop will cause blindness, if splashed in eye, unless eye is washed within a few seconds after contamination. Safety glasses are strongly recommended when mixing resin. Keep an eyewash bottle filled with clean water at the resin mixing station. In case of eye contact, immediately flush with plenty of clear water, and see a physician. Store in original closed container in a cool location. Protect from direct sunlight, heat, sparks, and open flame. Do not add to hot materials. Prevent contamination with foreign materials, especially readily oxidizable materials, accelerators, and promoters. When the container is emptied, it must be destroyed, and must not be reused for any purpose. Failure to observe these precautions may result in explosive decomposition. STODDARD-HAMILTON AIRCRAFT, INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-7 B. CATALYZED RESIN OR GELCOAT: Contact with fingers and hands poses no serious problem, but prolonged contact should be avoided. Tight fitting latex medical gloves can be used to avoid any contact with the skin. II. VAPORS AND DUST PARTICLES Avoid breathing the fiberglass particles while sanding or filing _the fiberglass. Use a non-toxic particle mask available at most hardware stores. The strong vapor smell of the resin before it cures is from the styrene in the resin as it evaporates away. Always laminate in a well ventilated area. High concentrations of styrene in small enclosed areas may cause nausea. Avoid breathing these vapors when high concentrations exist. We recommend the use of a vapor spray mask which is available at most hardware stores. We also recommend that construction be done in a garage or area separate from living quarters because of the vapors present. III. FLAMMABILITY The materials used in fiberglass construction are highly flammable, especially the acetone and catalyst. Keep them away from direct sunlight, heat, sparks, and open flame. Keep track of all materials and store in a cool, clean, well ventilated area. Make sure all containers are sealed when not in use. When resin gels and then exotherms enough heat can be generated under the right conditions to cause a fire. None of the lay ups on the Glasair pose a problem because they are not thick enough. The only time this could be a problem is when a large batch of resin is used in a container, coupled with high temperatures and a high catalyst percentage. DO NOT throwaway catalyzed resin before it has gelled, exothermed, and cooled. IV. PROPER RESIN MIXING SEQUENCE CoNap should never be mixed directly with MEKP catalyst. A violent reaction will occur which may result in fire or explosion. Resin is promoted in I gallon quantities only, because promoted resin has a shorter shelf life than unpromoted resin. Resin is first promoted with the CoNap, and then the DMA. This forms a master batch of promoted resin from which smaller quantities can be taken as needed. Just prior to use, the promoted resin is catalyzed with MEKP catalyst. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL I N F O R 1 ~ T I O N REVISION DATE VOLUME I PAGE 1-8 HINGE BREAKDOWN QTY LENGTH DESCRIPTION USED ON 4 8" MS2000l-PH4 Hinge Ailerons 4 12" MS2000l-PH4 Hinge Flaps 2 38" MS2000l-PH4 Hinge Belly Panel 6 5" MS2000l-PH4 Hinge Elevators 2 8" MS2000l-PH4 Hinge Rudder 2 l 4 ~ " MS2000l-PH4 Hinge Engine Cowling 1 4" MS2000l-PH4 Hinge Engine Cowling-Oil Access Panel 2 3 3 ~ " MS20257-P4 Hinge Engine Cowling 4 9" MS20253-P2 Hinge Pin Ailerons 4 13" MS20253-P2 Hinge Pin Flaps 2 39" MS20253-P2 Hinge Pin Belly Panel '6 6" MS20253-P2 Hinge Pin Elevators 2 9" MS20253-P2 Hinge Pin Rudder 2 l 5 ~ " MS20253-P2 Hinge Pin Engine Cowling 1 4" MS20253-P2 Hinge Pin Engine Cowling-Oil Access Panel We supply a total of 18 feet, 23 inches of MS2000l-PH4 hinge and 18 feet, 35-1/2 inches of MS20252-P2 hinge pin. The hinge comes in three 6 foot lengths and one 23 inch piece. The hinge pin comes in three 6 foot lengths and one 35-1/2" piece. NOTE: It is important to cut the hinge stock properly to use the supplied material to the best advantage. If not cut properly there will not be enough hinge for the airplane. Cut the hinge material as depicted below. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME' I PAGE 1-9 HINGE BREAKDOWN (CONT'D) Cut the Hinge and Hinge Pin as Described Below: HINGE HINGE PIN TL: 12" 12" 8" 8" 8" 8" 5" 5" 5" 71" 38" 12" 12" 8" 70" 38" 14.5" 14.5" 4" 71" 5" 5" 5" 8" 23" 13 13 13 9 9 9 5 71 " 39" 9" 9" 9" 5" 71" 39" 15.5" 13" 4" 71.5" 15.5" 5" 5" 5" 5" 35.5" USE: 6 ' 6' 6' 23" 6 ' 6 ' 6 ' 35.5" BUILDERS "HOT LINE" In order to provide the best service and support to our builders we have a toll free phone line to be used r h ~ Y for questionsrelating to construction of the Glasair. '. 1S line is available for use from 8:00 am to 4:00 pm, Pacific Time, Monday through Friday. You must have touch-tone telephone equipment to use this line. Here is how to call: If you live in the continental U.S. call 1-800-843-3313. ~ f u e n you hear the dial tone, dial 828879. If you live in Alaska or Hawaii, call 1-800-645-5557. When you hear the dial tone, dial 828879. If you live in Washington State, call 1-800-221-2106. When you hear the dial tone, dial 828879. We will not accept calls for other than questions relating to construction of the Glasair on this line. All orders for parts or materials, sales calls, or other business must be handled through our regular business lines. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFOroiATION REVISION DATE VOLUME I PAGE 1-10 FAA INSPECTION AND DOCUMENTATION REQUIREMENTS The FAA requires that certain documents and records be kept, including records of pre-cover inspection, during construction of a homebuilt aircraft. These requirements are detailed in FAA Advisory Circular 20-27C, which is available (free of charge) from: U. S. Department of Transportation Publications Section 442.32 Washington, D. C. 20590 This is a brief outline of all the major points covered in AC 20-27C. First, the builder must keep copies of invoices, receipts, and shipping documents for materials and kits used in construction of the aircraft. The FAA Inspector will want to see these documents when inspecting the aircraft prior to issuance of and airworthiness certificate. The builder must also keep a log of the construction and inspection of the aircraft as it is built. The FAA no longer performs pre-cover inspections; however, pre-cover inspections performed by some knowledgeable person, such as the builder himself or an EAA designee, are still required, and must be recorded in the construction log. The FAA will perform a final inspection of the aircraft before flight. In addition to inspecting the aircraft itself, the FAA will inspect the above mentioned documents and records. If the aircraft passes the inspection, and the necessary documents and records are in order, the inspector will issue a limited airworthiness certificate for a specific test period and area. The flight history of the aircraft, during the specified test period, must be recorded in a flight log. The length of each flight, the tests performed, and the outcome of the tests should be recorded. Notes should be made of any problems encountered during test flights and the steps taken to resolve the problems. Aerobatic maneuvers should be logged so the FAA can include these in the flight limitations when the unlimited airworthiness certificate is issued. After the flight test period has been flown off, the builder should present the construction and flight logs and the old limited airworthiness certificate to the FAA for issuance of an unlimited airworthiness certificate. If all the records are in order, the FAA will not inspect the aircraft at this time. If there are any questions concerning registration and certification we suggest contacting the local GADO or FSDO. A logbook system, specifically designed for aircraft homebuilders, is available from: Aerorecords 6854 Antiqua Way Sacramento, CA 95831 ~ STODDARD-HAMILTON AIRCRAFT,INCORI'ORATED ASSEMBL Y NAME MODEL GLASAIR TD GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-11 DEFINITIONS AND TERMINOLOGY 1.) ACCELERATOR: dimethylaniline or DMA; also termed promoter; one of the two ingredients added to the resin prior to catalysis. 2.) BIAS: cloth orientation to load paths, measured in degrees from the longitudinal axis of the pattern. 3.) CATALYSIS: the act of adding MEKP catalyst to the resin to cause it to cure. 4.) CATALYST: methyl ethyl ketone peroxide or MEKP; the final ingredient added to the resin to make it cure. A very hazardous liquid if improperly used. See the Safety Precaution under "MEKP CATALYST". 5.) CURE: the state of resin where it reaches full hardness and strength. 6.) EDGEBAND: the flat portion along the periphery of a composite panel. 7.) EXOTHERMIC REACTION: a chemical reaction where energy is released in the form of heat. 8.) FIBERGLASS: the trade name for glass fibers (consisting mainly of silicon, calcium, and aluminum dioxides); woven into various forms such as seam tape, bidirectional cloth, unidirectional cloth. 9.) FILL: direction of cloth with the lesser percentage of strength and quantity of fibers. 10.) GEL TIME: time it takes the resin to set up in the container after proper and thorough mixing with promoters, accelerators, and catalysts. 11.) GELATION: the beginning of the solidification of resin after catalysis. 12.) GELCOAT: white protective coating on all exposed outside fiberglass surfaces on the airplane, must be catalyzed prior to use. 13.) GREEN CURE: the point at which a laminate hardens enough to be able to cut it with a knife. Usually 15-45 minutes after gelation depending upon temperature. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED MODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME I PAGE 1-12 14.) LAMINATE: a layer or layers of cured fiberglass cloth impregnated with resin; the act of saturating. 15.) LAY-UP: a layer of fiberglass cloth that is being saturated with resin (noun); the act of saturating a piece of fiberglass cloth with resin (verb); used interchangeably with laminate. 16.) MILL FIBERS: very short glass strands or fibers in "powder" form. 17.) PVA: polyvinyl alcohol; a green water based coating found on the mold surface of parts used as a mold release for new molds, easily removed with water. 18.) PROMOTERS: cobalt naphthenate or CoNap (purple in color), and dimethylaniline or DMA (orange-yellow in color); also called an accelerator. These two ingredients are added to the resin prior to catalyzing it with MEKP to create a master promoted batch of resin. 19.) Q-CELL: inorganic micro-spheres (or glass bubbles) used to seal foam panels and fill cracks and corners. Comes in powder form, white in color, mixed with resin and applied to foam panels. 20.) RESIN: vinylester, used to saturate fiberglass cloth to bond parts together, must be promoted and then catalyzed prior to use (golden-brown in color). 21.) TYPICAL or (TYP.): used in illustrations to denote a similar situation, dimension, contour, etc. in another location on the drawing or illustration, such as a hole diameter or radius. 22.) WARP: direction of cloth weave with the greater percentage of strength and quantity of fibers. 23.) WORKING TIME: the time after catalysis and before the start of gelation, when the resin can be applied successfully to the fiberglass cloth. ~ STODDARD-HAMILTON AIRCRAFT. INCORPORATED PAGEMODEL GLASAIR TD ASSEMBLY NAME GENERAL INFORMATION REVISION DATE VOLUME I 1-13 -LIST OF Ri::VISIONS -PAGE NO. REVISION LEITER DATE-F-1S F-36 F-39 F-4S F-49 A A A A A 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 G-1S G-16 G-17 G-36 G-41 G-54 G-114 G-115 G-119 G-123 G-125 G-127 G-151 G-169 G-171 G-199 G-200 A A A A A A A A A A A A A A A A A 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 6/30/86 H-7 H-10 H-66 H-78 A A A A 6/30/86 6/30/86 6/30/86 6/30/86 1-6 1-15 B B 10/31/86 10/31/86 - ~ -STODDARD-HAMILTON AIRCRAFT INCORPORATED PAGE DArE MODEL ASSEMBL Y NAME REVISION VOLUME [ 1-1 5 GLASAIR GENERAL INFORMATION 6/30/8f1 B